PRODUCT AND SERVICES

MANUFACTURING PROCESSES

PRODUCT AND SERVICES

ALL INDUSTRIES MAY BE TREATED AS SERVICE INDUSTRIES TO AN EXTENT, SOME ORGANIZATIONS MORE THAN OTHERS. EVEN PURELY MANUFACTURING ORGANISATIONS DO NOT JUST SELL A PRODUCT BUT PROVIDE SOME FORM OF BACK UP SUCH AS AFTER SALES SERVICE, ADVICE, WARRANTY, REPAIR, INSTALLATION, OR TRAINING. ON THE OTHER HAND, EVEN IN PURE SERVICE INDUSTRIES SUCH AS BANKS, HOSPITALS, EDUCATION, AND CONSULTANCIES, THERE IS OFTEN A PRODUCT WHICH CHANGES HANDS. FOR EXAMPLE, BANKS TALKS ABOUT NEW PRODUCT DEVELOPMENT, BECAUSE THEY DO HAVE PRODUCTS LIKE - LOAN SCHEME, VARIOUS TYPE OF CREDIT CARDS, OTHER TYPES OF MONETARY INSTRUMENTS,ETC. HOSPITALS PROVIDE PRODUCTS TO THE PATIENTS IN THE FORM OF DIAGNOSES AND PRESCRIPTION REPORTS SIMILARLY, CONSULTANCIES PROVIDE REPORTS OF THEIR FINDINGS, ANALYSIS, AND RECOMMENDATIONS TO THE CLIENT ORGANISATIONS. IN AN EDUCATIONAL SET UP, A STUDENT MAY SEE THE DEGREE OR DIPLOMA AS THE END PRODUCT, WHILE THE INSTITUTIONS PERCEPTION MAY BE ENTIRELY DIFFERENT, AS IT MAY CONSIDER AN ENLIGHTENED STUDENT WITH APPROPRIATE KNOWLEDGE AND SKILLS AS THE END PRODUCTS.
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PRODUCT AND SERVICES

IN MANUFACTURING, WE GET TANGIBLE AND IDENTIFIABLE PRODUCT, WHICH IS OBTAINED AS A RESULT OF SERIES OF TRANSFORMATION PROCESSES SUBJECTED TO IT. IN SERVICES, THE END PRODUCT IS OFTEN INTANGIBLEN AMUSEMENT IN A THEME PARK, HOSPITALITY IN A HOTEL, GOOD EDUCATION ETC. - BUT IT IS JUST AS REAL. WHEN WE BUY A TELEVISION, WE IGNORE ITS MANUFACTURING PROCESSES , BUT FOCUS ONLY UPON THE FEATURES OF THE END PRODUCT. THE MAIN DIFFERENCE IS THAT IN SERVICES IT IS THE CUSTOMER THAT HAS BEEN PROCESSED. IN THE SERVICE INDUSTRY, IT IS OFTEN THE PROCESSES THAT ARE BOUGHT RATHER THAN THE PRODUCT.
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PRODUCT AND SERVICES

SOME ORGANIZATIONS MAY BE CONSIDERED AS OFFERING A HYBRID OF PRODUCTS AND SERVICES TO ITS CUSTOMERS. FOR EXAMPLE, IN A RESTAURANT, A CUSTOMER EXPECTS GOOD PREPARATIONS OF FOOD OFFERED ( A PRODUCT ) AND GOOD AMBIENCE OF THE PLACE, GOOD BEHAVIOUR, AND QUICK SERVICE ON PART OF THE WAITER ( A SERVICE ) . SIMILARLY, WHILE FLYING IN AN AEROPLANE A CUSTOMER GETS A PRODUCT FOR USE ( A SEAT IN THE PLANE ) AND SERVICES SUCH AS MEDICAL AID, REFRESHMENTS, ETC. FROM THE HOSTESSES,

CONCEPT OF PRODUCT DESIGN

MANUFACTURABILITY REVERSE ENGINEERING

STANDARDIZATION

RESEARCH & DEVELOPMENT

PRODUCT LIFE CYCLE

CONCEPTS IN PRODUCT DESIGN

ROBUST DESIGN

CONCURRENT ENGINEERING COMPUTER AIDED DESIGN (CAD)

MODULAR DESIGN

THE TRANSFORMATION PROCESS

PRODUCTION AND OPERATIONS MANAGEMENT

PRODUCTION AND OPERATION MANAGEMENT (POM) IS DEFINED AS THE DESIGN, OPERATION, AND IMPROVEMENT OF THE TRANSFORMATION PROCESS, WHICH CONVERTS THE VARIOUS INPUTS INTO THE DESIRED OUTPUT OF PRODUCTS AND SERVICES. THE TERM PRODUCTION AND OPERATIONS MANAGEMENT IS BEING INCREASINGLY REPLACED BY SIMPLY OPERATIONS MANAGEMENT, AS THE PRODUCTION FUNCTION RELATING TO MANUFACTURING ORGANIZATION HAS BECOME A PART OF OPERATIONS. OPERATION MANAGEMENT IS A BROAD TERM WHICH INCLUDES MANUFACTURING AS WELL AS SERVICE ORGANIZATIONS. OPERATIONS MANAGEMENT ALSO HIGHLIGHTS THE INCREASING IMPORTANCE OF THE SERVICE INDUSTRY IN THE OVERALL BUSINESS ENVIRONMENT. THERE IS A GROWING NEED FOR THE APPLICATION OF THE PRINCIPLES OF OPERATIONS MANAGEMENT IN THE SERVICE INDUSTRY.
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PROCESS DESIGN
THE TRANSFORMATION PROCESS IS USED TO CONVERT INPUTS INTO DESIRED OUTPUTS. THE PROCESS CAN BE OF VARIOUS TYPES CONTINUOUS PROCESS

TYPES OF PROCESSES

MASS & FLOW PRODUCTION (SEMI CONTINUOUS) (REPEATITIVE / ASSEMBLY) PROCESS

BATCH PROCESS INTERMITTENT PROCESS JOB SHOP PROJECTS

DEGREE OF REPETITIVENESS
JOBBING BATCH MASS

PROCESS
PROJECT PRODUCTION CONTINUOUS PRODUCTION

ONE

MANY

LOW SKILLED LABOUR, HIGHLY AUTOMATED MASS PRODUCTION PROCESS USING SPECIAL PURPOSE MACHINES AND SIMPLE PPC SYSTEM HIGHLY SKILLED LABOUR, GENERAL PURPOSE MACHINES DETAILED AND 9 SOPHOSTICATED PPC SYSTEM

CONTINUOUS PROCESS
THE CONTINUOUS PROCESS AS THE NAME SUGGESTS IS CONTINUOUS IN NATURE. THE SET UP TIME FOR STARTING SUCH PROCESSES IS USUALLY VERY LONG, AND ONCE STARTED, THEY CONTINUE FOR A LONG DURATION.

THE PRODUCTS PRODUCED BY SUCH A PROCESS ARE HIGHLY STANDARDIZED WITH ALMOST NO VARIETY, AND ARE MEASURED ON A CONTINUOUS BASIS (TONS PER DAY, METER LENGTHS PER DAY ETC.) RATHER THAN IN TERMS OF DISCEET UNITS.
FOR EXAMPLE, UREA, CHEMICALS STEEL, PLASTIC, SUGER, TEXTILES, DETERGENTS, ETC. INDUSTRIES ARE BASED ON THE CONTINUOUS PROCESS AND ARE, THEREFORE, KNOWN AS PROCESS INDUSTRIES
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CHARACTERISTIC OF CONTINUOUS MANUFACTURING

1. 2. 3. 4. 5. 6. 7. 8. CONTINUOUS PRODUCTION RUNS CONTINUOUS FLOW OF MATERIALS BALANCED / SYNCHRONIZED MANUFACTURING CYCLE TIME SPECIAL PURPOSE MACHINES AND PRODUCT LAYOUT. SEMI SKILLED LABOUR AVERAGE COMPETENT KNOWLEDGEABLE SUPERVISION VERY LITTLE WORK IN PROGRESS LIMITED FUNCTIONS OF PRODUCTION PLANNING CONTROL
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SEMI CONTINUOUS PROCESS

MASS AS WELL AS FLOW PRODUCTION, ALSO KNOWN AS SEMI CONTINUOUS PROCESS, ARE CHARACTERISED BY MANUFACTURING OF SEVERAL NUMBER OF STANDARD PRODUCTS, PRODUCED AND STOCKED IN THE WAREHOUSE AS FINISHED GOODS AWAITING SALES. THE GOODS UNDER MASS PRODUCTION ARE MANUFACTURED EITHER AT A SINGLE OPERATION OR A SERIES OF OPERATIONS ON ONE MACHINE. AND GOODS UNDER FLOW PRODUCTION ARE MANUFACTURED BY A SERIES OF OPERATIONS ON DIFFERENT MACHINES, ARRANGED AS PER SEQUENCE OF OPERATIONS. SEMI CONTINUOUS PROCESSES ARE ASSEMBLY PROCESSES, WHICH ARE REPEATATIVE IN NATURE. THEY PRODUCE HIGH VOLUME OF OUTPUT AND THE PRODUCTS PRODUCED HAVE LITTLE VARIETY. FOR EXAMPLE, AUTOMOBILES, ELECTRONIC ITEMS, WHITE GOODS, ETC. THESE PROCESSES REQUIRE HIGHLY SPECIALIZED MACHINES, SEMI SKILLED WORKERS, AND RESULT IN LOW COST PER UNIT.
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INTERMITTENT PROCESS
AS THE NAME SUGGESTS, INTERMITTENT PROCESSES STOP AT REGULAR INTERVALS OF TIME BECAUSE THE PRODUCT REQUIRES PROCESSING ON VARIETY OF MACHINES. THE PRODUCTS PRODUCED ARE OF DIFFERENT VARIETIES, THUS MAKING THE PRODUCTION PROCESS SLOW IN COMPARISON TO THE CONTINUOUS / SEMI CONTINUOUS PROCESS. INTERMITTENT PROCESSES ARE OF TWO TYPES

1. BATCH PROCESS
2. JOB SHOP
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BATCH PROCESS
THIS PROCESS IS ADOPTED WHEN BATCHES OR LOTS OF ITEMS ARE TO BE PRODUCED USING THE SAME SET OF MACHINES IN THE SAME SEQUENCE. FOR EXAMPLE, IN A BAKERY, A BATCH OF SALTED BISCUITS MAY BE MADE IN THE OVEN, FOLLOWED BY A BATCH CHOCOLATE, FOLLOWED BY A BATCH OF BREAD AND SO ON. THE EQUIPMENT USED IS THE SAME IN ALL THE CASES WITH THE SAME PROCESSING STEPS, BUT CLEANING AND ADJUSTMENTS OF EQUIPMENT MAY BE REQUIRED AFTER EACH PRODUCTION RUN.
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CHARACTERISTICS OF BATCH PRODUCTION

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. SHORT RUNS SKILLED LABOUR IN SPECIFIC TRADES SUPERVISOR TO POSSES KNOWLEDGE OF A SPECIFIC PROCESS. LIMITED SPAN OF CONTROL GENERAL PURPOSE MACHINES AND PROCESS TYPE LAY OUT MANUAL MATERIAL HANDLING MANUFACTURING CYCLE TIME AFFECTED DUE TO QUEUES LARGE WORK IN PROGRESS FLEXIBILITY OF PRODUCTION SCHEDULES NEED TO HAVE GOOD PRODUCTION PLANNING AND CONTROL
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JOB SHOP
THIS PROCESS CAN HANDLE A LARGE VARIETY OF PRODUCTS THAN THE BATCH PROCESS. THE PRODUCTS MAY BE SO DIFFERENT FROM EACH OTHER THAT THEIR PROCESSING REQUIREMENTS MAY BE VARIED PROCESSES, ON DIFFERENT MACHINES, IN DIFFERENT SEQUENCES, AND WITH DIFFERENT PROCESSING TIME. THE BATCHES OF ITEMS PRODUCED IN JOB SHOP MAY VARY IN SIZE FROM LARGE, COMPRISING MANY UNITS, TO VERY SMALL, COMPRISING A SINGLE UNIT. FOR EXAMPLE, IN A RESTAURANT EVERY CUSTOMER GIVES A DIFFERENT ORDER OF DISHES, WHICH ARE PREPARED BY DIFFERENT COOKS USING DIFFERENT UTENSILS, OVENS, ETC. AND DIFFERENT RECIPES. JOB SHOP RESULTS IN LOW VOLUME OF OUTPUT AT A GIVEN TIME AND THUS COSTLIER PRODUCTS COMPARED TO CONTINUOUS PROCESSES
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CHARACTERISTIC OF JOBBING PRODUCTION

1. 2. 3. 4. 5. 6. 7. 8. SMALL PRODUCTION RUNS DISCONTINUOUS FLOW OF MATERIALS DISPROPORTIONATE MANUFACTURING CYCLE TIME GENERAL PURPOSE MACHINES AND PROCESS LAYOUT. HIGHLY SKILLED LABOUR HIGHLY COMPETENT KNOWLEDGEABLE SUPERVISION LARGE WORK IN PROGRESS LIMITED FUNCTIONS OF PRODUCTION PLANNING CONTROL
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PROJECTS
PROJECTS ARE PROCESSES THAT HANDLE VERY COMPLEX AND UNIQUE SETS OF ACTIVITIES OR TASKS, WHICH HAVE TO BE COMPLETED IN A LIMITED SPAN OF TIME. FOR EXAMPLE, R & D PROJECTS, CONSTRUCTION OF PLANTS, BUILDING COMPLEXES, IMPLEMENTATION OF SPECIALIZED SOFTWARE IN AN ORGANIZATION, ETC.
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CHARACTERISTIC OF PROJECT PRODUCTION

1.

2.

3.

DEFINITE BEGINNING AND DEFINITE END: EACH PROJECT HAS A DEFINITE BEGINNING AND A DEFINITE END. NON UNIFORM REQUIREMENT OF RESOURCES: REQUIREMENT OF RESOURCES FOR PROJECT PRODUCTION IS NOT UNIFORM. AT THE END OF THE PROJECT, RESOURCES FROM THE PROJECT ARE REDEPLOYED ELSEWHERE IN OTHER PROJECTS. EVEN DURING THE LIFE OF THE PROJECT, REQUIREMENT OF RESOURCES IS NOT UNIFORM. GENERALLY RESOURCE REQUIREMENT (MEN, MATERIALS, EQUIPMENT, ETC.) IN THE BEGINNING OF THE PROJECT IS LOW WHICH BUILDS UP FAST WITH THE PROGRESS OF THE PROJECT AS MORE AND MORE RESOURCES ARE ABSORBED, THEN IT LEVELS OFF UNTIL THERE IS GRADUAL CUT BACK AS THE PROJECT APPROACHES COMPLETION. INVOLVEMENT OF DIFFERENT AGENCIES: A PROJECT GENERALLY INVOLVES MANY TASKS, EACH HAVING ITS OWN SPECIALIZATION TO BE PERFORMED BY DIFFERENT AGENCIES. THE TASKS GENERALLY HAVE STRICT PRECEDENCE (I.E. CERTAIN TASKS MUST BE COMPLETED BEFORE THE NEXT BEGINS) AND SUCH COORDINATION BETWEEN AGENCIES IS OF UTMOST IMPORTANCE. 19

CHARACTERISTIC OF PROJECT PRODUCTION

4. FIXED POSITION LAYOUT: WHERE THE OUTPUT OF A PROJECT IS A PRODUCT, SUCH PRODUCTS ARE GENERALLY CHARACTERISED BY IMMOBILITY DURING TRANFORMATION. OPERATIONS ON SUCH PRODUCTS ARE CARRIED OUT IN FIXED POSITION ASSEMBLY TYPE OF LAYOUT WHICH CAN BE OBSERVED IN PRODUCTION OF SHIPS, LOCOMOTIVE, AIRCRAFT, CONSTRUCTION OF ROADS / BUILDINGS ETC. HIGH COST OVERRUNS: OFTEN DELAYS TAKE PLACE IN THE COMPLETION OF THE PRJECTS. SUCH DELAYS ARE GENERALLY VERY EXPENSIVE DUE TO ESCALATION IN THE COST OF FACTORS OF PRODUCTION AND INCIDENT OF PENALTIES.
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5.

CHARACTERISTIC OF PROJECT PRODUCTION

6. PERSONNEL PROBLEMS: PROJECT PRODUCTION HAS MANY PERSONNEL RELATED PROBLEMS NAMELY WHEN THERE IS A FAST BUILD UP, STAFF IS EITHER BORROWED FROM OTHER DEPARTMENTS OR HIRED FOR SHORT DURATION. THEREFORE, PERSONNEL INVOLVEDIN THE PROJECT HAVE LIMITED (OR SHORT LIVED) INTEREST IN THE PROJECT. SINCE SUCH PROJECTS HAS A LIMITED DURATION, THE STAFF STARTS SPENDING MORE TIME FOR GETTING PREPARED FOR THE NEXT PROJECT. SITE FOR THE PROJECT MAY BE IN THE UNDERDEVELOPED REGION AND IT MAY CHANGE FROM PROJECT TO PROJECT WHICH CAUSES DISLOCATION OF THE NORMAL LIFE. 7. SCHEDULING AND CONTROL : BECAUSE OF LARGE NUMBER OF ACTIVITIES, INVOLVEMENT OF DIFFERENT AGENCIES AND STRICT PRECEDENCE REQUIREMENTS, SCHEDULING AND CONTROL ASSUME GREAT IMPORTANCE. SOME NETWORK PLANNING TECHNIQUES LIKE PERT AND CPM HAVE BEEN FOUND TO BE VERY USEFUL TO OVERCOME THE PROBLEMS MENTIONED ABOVE. 21